Switching monitoring device

ABSTRACT

A switching monitoring device for monitoring a switching operation of a relay switching contact of a relay includes a control terminal, a controller, and an impedance circuit. The control terminal is configured to apply a control signal for switching the relay switching contact to the relay switching contact. The controller is configured to produce an excitation signal. The impedance circuit has a signal input and a signal output, and the controller applies the excitation signal to the signal input. The impedance circuit converts the excitation signal into a switching monitoring signal and outputs the switching monitoring signal at the signal output for application to the relay switching contact. The controller is further configured to detect a change in a signal present at the impedance circuit and, if the change in the signal is present, detect the switching operation of the relay switching contact.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation of U.S. patent applicationSer. No. 17/055,893 by Scholz et al., entitled “SWITCHING MONITORINGDEVICE” filed Nov. 16, 2020, which is a national phase entry under 35U.S.C. 371 of International Patent Application No. PCT/EP2019/063672 byScholz et al., entitled “SWITCHING MONITORING DEVICE,” filed May 27,2019; and claims the benefit of German Patent Application No. 10 2018114 425.3 by Scholz et al., entitled “SCHALTÜBERWACHUNGSVORRICHTUNG,”filed Jun. 15, 2018, each of which is assigned to the assignee hereofand is incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a switching monitoring device formonitoring a switching operation of a relay switching contact.

BACKGROUND

In electrical automation, actuators can each be switched with a relay.It may be necessary that an actual switching through of a relayswitching contact is detected. Such detected feedback is usuallyimplemented via the switching of the relay using additional auxiliarycontacts. Alternatively, a forced contact control can be implemented toprevent incorrect switching of the relay. In the event of a faulty relayswitching contact, which has, for example, defective, in particularwelded buttons, the switching of further relay switching contacts and/ora connection of the welded buttons to another button can be preventedwith the forced contact control. A forced contact control and/orfeedback by means of auxiliary contacts can disadvantageously involveincreased production costs in the manufacture of a relay.

SUMMARY

It is the object of the present disclosure to provide a more efficientswitching monitoring device which provides information about theswitching state of a relay switching contact, in particular as afunction of the relay control.

This object is achieved by the features of the independent claim.Advantageous implementations of these features are the subject matter ofthe dependent claims, the description and the accompanying figures.

The present disclosure is based on the knowledge that the above objectcan be solved by a switching monitoring device which is adapted to applya switching monitoring signal, in particular in the form ofhigh-frequency auxiliary power, to the relay switching contact by meansof a signal generator and a transmitter connected downstream of thesignal generator. The switching monitoring signal is produced by thesignal generator and coupled into the load circuit of the relay by thetransmitter. A change in the impedance of the load circuit, inparticular by switching the relay switching contact, is fed back to thesignal generator via the transmitter and produces a signal changebetween the signal generator and the transmitter, which can be used todetect switching of the relay switching contact.

According to a first aspect, the disclosure relates to a switchingmonitoring device for monitoring a switching operation of a relayswitching contact of a relay. The switching monitoring device has acontroller which is adapted to produce an excitation signal and acontrol terminal which is adapted to apply a control signal forswitching the relay switching contact to the relay switching contact.

The switching monitoring device further comprises an impedance circuithaving a signal input and a signal output, wherein the controller isadapted to apply the excitation signal to the signal input. Theimpedance circuit is adapted to convert the excitation signal into aswitching monitoring signal and to output the switching monitoringsignal at the signal output for application to the relay switchingcontact.

The controller is also adapted to detect a change in a signal present atthe impedance circuit and if the change in signal is present, to detecta switching operation of the relay switching contact.

In one example, the signal comprises the excitation signal and/or theswitching monitoring signal.

In one example, the controller can be adapted to detect a change in theexcitation signal present at the impedance circuit and to detect aswitching operation of the relay switching contact when the change inthe excitation signal is present. In particular, the controller can beadapted to detect a change in the excitation signal instead ofmonitoring the change in the switching monitoring signal. In addition tothe impedance circuit, the controller can have a further signalmonitoring circuit for monitoring a change in the switching monitoringsignal. This signal monitoring circuit can be adapted to detect a changein the switching monitoring signal by means of capacitive or inductivecoupling.

With the monitoring of the relay switching contact by the switchingmonitoring device, switching information relating to the transition ofthe relay switching contact between a first switching state in which therelay switching contact is electrically non-conductive and a secondswitching state in which the relay switching contact is electricallyconductive can be produced when the control signal is applied to therelay. This can ensure that the relay switches with the control signaland that there is accordingly no fault in the relay switching contactand/or at a magnet system of the relay. Accordingly, if the controlsignal is applied to the relay and if the relay switching contact failsto switch, a malfunction of the relay can be determined. Switching ofthe relay when the switching signal drops can also be detected.

The switching monitoring device achieves the advantage that under theaspect of functional safety, in particular in accordance with the IEC61508 standard, the switching state of the relay switching contact canbe clearly detected. Correspondingly, an increased diagnostic coveragecan be achieved.

In one example, the relay is adapted to transmit signals in a firstfrequency range and the switching monitoring signal is in a secondfrequency range, wherein the second frequency range has higherfrequencies than the first frequency range, and wherein the impedancecircuit has a higher impedance in the first frequency range than in thesecond frequency range.

The impedance circuit can form a frequency filter, in particular abandpass filter, which has a lower impedance for the switchingmonitoring signal and/or the excitation signal than for electricalsignals with other frequencies. Accordingly, coupling in of electricalsignals from a voltage source and/or from a further signal source with acorresponding power transmission can be prevented and/or attenuated. Forexample, the first frequency range can include frequencies from 0 Hz to100 Hz and/or the second frequency range can include frequencies above10 kHz, in particular the frequency range from 100 kHz to 500 kHz. Withthe higher impedance in the first frequency range, a current flow on theoutput side can in particular be reduced. Correspondingly, by couplingthe signal input to the signal output in the first frequency range, acurrent flow on the input side can be reduced.

The impedance circuit can in particular have a two-port which is formedby a 2×2 impedance matrix. The impedance at the signal output can behigher for low frequencies, for example in the frequency range from 10Hz to 100 Hz, in particular 50 Hz, than for high frequencies, forexample in the frequency range from 100 kHz to 1 MHz, in particular 500kHz. For example, the impedance can be 13 MOhm at a frequency of 50 Hzand 3 kOhm at a frequency of 500 kHz. Correspondingly, afrequency-dependent impedance difference between the first frequencyrange and the second frequency range of three to four orders ofmagnitude can be achieved.

In one example, the controller is adapted to produce the excitationsignal in the second frequency range. This has the advantage that theimpedance circuit can efficiently convert the excitation signal into theswitching monitoring signal due to the lower impedance in the secondfrequency range.

In one example, the controller comprises a measuring circuit formonitoring the change in the excitation signal. The measuring circuitcan in particular be adapted to detect a change in amplitude of theexcitation signal, for example a change in voltage amplitude and/or achange in current amplitude.

Furthermore, the measuring circuit can be adapted to detect a frequencydeviation of the frequency of the excitation signal. Furthermore, themeasuring circuit can have an analog-digital converter and/or ameasuring signal amplifier in order to further process the measuringsignal, in particular a current and/or voltage change in the excitationsignal.

In one example, the controller comprises a signal generator forgenerating the excitation signal. The signal generator can in particularbe adapted to produce the excitation signal in the form of a periodicvoltage signal. For example, the excitation signal can have arectangular, sawtooth or sinusoidal signal shape. The frequency of theexcitation signal can be set to a predetermined value by means of thesignal generator. Furthermore, the signal generator can be adapted toproduce the excitation signal with a fixed frequency value.

In one example, the measuring circuit has a current sensor which isconnected between the signal generator and the impedance circuit,wherein the current sensor is adapted to detect a current flow betweenthe signal generator and the impedance circuit and to provide it to thecontroller as a measured current value, and wherein the controller isadapted to detect a change in the current flow between the signalgenerator and the impedance circuit on the basis of the measured currentvalue.

The current sensor can be formed by a resistor, in particular an ohmicresistor, at which a current flow between the signal generator and theimpedance circuit can be measured in the form of a measurement voltage.The controller can further include a voltage measuring device which isadapted to detect the measurement voltage.

Further, the controller can comprise a voltage sensor which is adaptedto detect a change in a voltage amplitude of the excitation signal inorder to detect a switching of the relay switching contact.

In one example, the impedance circuit is adapted to galvanicallyseparate the relay switching contact from the signal generator and/orthe controller. The relay switching contact can have an electrical powerapplied to it, wherein it is possible for this electrical power to beprevented from being coupled into the controller and/or the signalgenerator by means of the galvanic isolation in the impedance circuit.This electrical power can in particular be greater than a power whichthe signal generator applies on the impedance circuit.

In one example, the impedance circuit comprises a transformer with aprimary-side coil and a secondary-side coil, wherein the secondary-sidecoil is connected in parallel to the relay switching contact, andwherein the primary-side coil is connected to the signal generator.

The transformer can in particular be adapted to convert the excitationsignal into the switching monitoring signal, wherein a current amplitudeand/or a voltage amplitude of the switching monitoring signal as afunction of the winding ratio of the primary-side coil to thesecondary-side coil is proportional to a current amplitude and/or avoltage amplitude of the excitation signal. The primary-side coil andthe secondary-side coil can be coupled electromagnetically so thatchanges in the switching monitoring signal by means of the transformercan be applied to the input side of the excitation signal.

If the relay switching contact is in the first switching state, theremay not be a low-impedance connection for the switching monitoringsignal, so that a current with a lower current intensity than in thesecond switching state can flow through the secondary-side coil.

The capacitor arranged in parallel to the relay switching contact canform an oscillating circuit with the secondary-side coil with apredetermined resonance frequency. This oscillating circuit can haveless damping with the relay switching contact in the second switchingstate than with the relay switching contact in the first switchingstate. Accordingly, when the oscillating circuit is excited by thesignal generator, an oscillation amplitude of the oscillating circuitwith the relay switching contact in the second switching state can behigher than an oscillation amplitude of the oscillating circuit with therelay switching contact in the first switching state. The controller canbe adapted to detect this change in amplitude of the oscillation bymeans of a resistor arranged between the signal generator and the signalinput.

In one example, an additional electromagnetic coil can be arranged onthe primary-side coil of the transformer, which is adapted to detect achange in the excitation signal in the event of a change in theswitching monitoring signal by switching the relay switching contact.The controller can be adapted to evaluate a signal induced in theadditional electromagnetic coil in order to detect a switching of therelay switching contact. The additional electromagnetic coil can bearranged next to the primary-side coil on a ferromagnetic core of thetransformer. In one example, the further electromagnetic coil can atleast partially enclose the primary-side coil, in particular it can bewound over the primary-side coil.

In one example, the impedance circuit has a capacitor which is arrangedin series with the secondary-side coil, wherein the capacitor is adaptedto form a reactance for alternating current voltage signals which areapplied to the relay switching contact.

The impedance circuit can act on the relay switching contact with an inparticular periodic switching monitoring signal. In the first switchingstate, an impedance at the signal output can be determined by thecapacitor. In the second switching state, the impedance at the signaloutput can be lower than the impedance at the signal output when therelay switching contact is in the first switching state. With a lowerimpedance at the signal output, a current intensity of the currentflowing through the signal output of the impedance circuit can begreater than with a higher impedance at the signal output. The impedancecircuit can be adapted to couple a corresponding change in currentintensity to the signal input, so that a current intensity of a currentflowing through the signal input increases with a reduced impedance onthe output side.

Furthermore, when the relay switching contact is switched, a voltageamplitude of the switching monitoring signal can change, wherein uponchange in the voltage amplitude of the switching monitoring signalchanging a current and/or voltage amplitude of the excitation signal canchange.

The capacitor can also form a reactance for alternating current voltagesignals which are produced by a voltage source and are applied to therelay switching contact. Furthermore, the capacitor can be adapted toreduce a power loss at the signal output and/or leakage currents whichcan flow with the relay switching contact in the first switching statethrough the signal output.

The capacitor can be adapted to withstand an alternating voltage and/ora direct voltage of 230 V including expected transients in anon-destructive manner.

In one example, the capacitor can be formed by a plate capacitor in theform of conductor tracks on a printed circuit board. The properties ofthe capacitor can be determined by the circuit board material and/or thecircuit board thickness, so that a defined dielectric strength can beachieved by a distance between two conductor track sections and/orconductor surfaces. The circuit board material can in particular be FR4,which is formed from a glass fiber fabric, in particular with adi/tetra-epoxy matrix.

In one example, the signal input is bipolar with a first inputconnection and a second input connection and the signal output isbipolar with a first output connection and a second output connection,and wherein a first capacitor is arranged between the first outputconnection and the first input connection, and wherein a secondcapacitor is arranged between the second output connection and thesecond input connection in order to capacitively couple the switchingmonitoring signal to the relay switching contact.

In one example, the impedance circuit has an inductance, which isconnected downstream of the first capacitor, wherein the inductanceforms an oscillating system with the first capacitor between the firstoutput connection and the first input connection.

In one example, the switching monitoring device comprises a firstcoupling capacitor, a second coupling capacitor and a signal monitoringcircuit. The first coupling capacitor can be connected to the firstoutput connection and the second coupling capacitor can be connected tothe second output connection, and the coupling capacitors are connectedto the signal monitoring circuit and are adapted to convert theswitching monitoring signal into a test signal and provide the testsignal to the signal monitoring circuit, and/or wherein the signalmonitoring circuit is adapted to detect a change in the test signal anddetect a switching operation of the relay switching contact when thechange in the test signal is present.

Furthermore, the first coupling capacitor, the second coupling capacitorand/or the signal monitoring circuit can be integrated into thecontroller. In one example, the impedance circuit can comprise thecoupling capacitors.

In one example, the control can be connected to the control terminal andis adapted to produce a control signal for switching the relay switchingcontact and/or to apply the control signal to the control terminal.

The inductance can in particular be an electromagnetic coil which has anelectrical inductance which is matched to the capacitance of theupstream capacitor in such a way that the combined impedance of theelectromagnetic coil and the capacitor is minimal at a resonancefrequency. The signal generator can be adapted, for example, to producethe excitation signal with the resonance frequency.

In one example, the impedance circuit has a further inductance, which isconnected downstream of the second output connection, the furtherinductance forms a further oscillatory system with the second capacitorbetween the second output connection and the second input connection.

In one example, the impedance circuit is adapted to apply the switchingmonitoring signal to the relay switching contact in the form ofhigh-frequency auxiliary energy, which in particular has a frequency inthe range from 10 kHz to 1 MHz. The signal generator preferably producesthe excitation signal with a frequency of 100 kHz to 500 kHz, which canin particular be a square-wave clock signal. The frequency of theexcitation signal can be fixed and/or predetermined by the controller.The impedance circuit can be adapted to convert the excitation signalwith a coupling frequency into the switching monitoring signal with thecoupling frequency.

In one example, the controller comprises a switching controller which isadapted to produce the control signal for switching the relay switchingcontact and to apply a control signal to a magnet system of the relay,in order to switch the relay switch contact.

The controller can also be adapted to supply the signal generator withelectrical energy. Activation of the relay can be coupled withgeneration of the excitation signal by the signal generator, so that,for example, the excitation signal can be produced at the same time asthe activation of the relay and the switching monitoring signal can beapplied to the relay switching contact.

In one example, the controller is adapted to apply the control signal tothe signal generator, and the signal generator is adapted to produce theexcitation signal, which the switching signal. This has the advantagethat the same electrical signal, with is also used to control the relay,can be fed to the signal generator. Accordingly, a separate energysupply for the signal generator and/or the controller can be omitted.

In one example, the controller can be adapted to detect a currentintensity of the switching signal and/or a current intensity of thecurrent flowing through a relay coil of the magnet system, in particularby means of a shunt resistor.

The relay switching contact can have a typical switch-on delay of 1 msto 50 ms, whereby with a simultaneous activation of the relay and thesignal generator with the activation signal, the switching monitoringsignal is applied to the relay switching contact before the relayswitching contact changes between the first switching state and thesecond switching state according to the activation signal. The signalchain from the signal generator via the impedance circuit to the relayswitching contact can accordingly have a shorter signal propagation timethan the switch-on delay of the relay.

Furthermore, the signal generator can be adapted to continue producingthe excitation signal after a drop in the control signal for a timeinterval which is in particular greater than a typical switch-off delayof the relay, in order to detect a change in the relay switching contactfrom the second switching state to the first switching state.

The switching monitoring device can be adapted to apply a relay controlsignal applied to the controller for controlling the relay to the signalgenerator, the impedance circuit and/or the magnet system of the relay,in order to supply energy to the respective component. Accordingly, aseparate energy source and/or energy supply for the signal generator,the impedance circuit and/or the controller can be omitted, since thesecan be directly supplied with electrical energy with the relay controlsignal.

In one example, the signal generator is adapted to produce theexcitation signal in the form of a periodic clock signal, and thecontroller is adapted to detect a time interval between producing theexcitation signal and a change in the excitation signal when theimpedance at the signal output changes, based on the constant period ofthe excitation signal, in order to detect a switching time delay of therelay switching contact.

The controller can in particular be adapted to detect a number ofperiods and/or clock cycles of the excitation signal and to detect thetime interval between the generation of the excitation signal andswitching of the relay switching contact in accordance with the fixedfrequency of the excitation signal. When the relay switching contact isswitched, an impedance on the output side can change, which causes achange in the excitation signal. The change in the excitation signal canbe detected by the controller by means of a sensor in order to determinea switching of the relay switching contact and an end of the timeinterval between relay activation and switching of the relay switchingcontact.

The controller can also be adapted to control the signal generatorbefore the relay switching contact switches. Accordingly, the switchingmonitoring signal can be applied to the relay switching contact during aswitching-on process of the relay switching contact and/or during aswitching-off process of the relay switching contact. The switchingmonitoring signal can advantageously be switched off while the relayswitching contact is in the first switching state or the secondswitching state. In particular, the switching monitoring signal is onlypresent during a switching time in which the relay switching contactchanges between the first switching state and the second switchingstate.

In one example, the controller has a control output, and the controlleris adapted to provide a status signal at the control output, which isactive after the relay switching contact is switched on and is inactiveafter the relay switching contact is switched off.

This achieves the advantage that status signals from a plurality ofSwitching monitoring devices can be aggregated at a central point inorder to switch a plurality of relays non-centrally and in particularremotely from the installation location of the respective relay of theplurality of relays.

The control output can also be an error signaling contact and/or animage of the relay switching contact. Furthermore, the control outputcan include an analog and/or digital interface which is adapted totransmit information about the relay and the switching state of therelay.

In one example, the switching monitoring device comprises a firstdamping element and the signal output has a first output connection,which is followed by the first damping element, in order to dampenhigh-frequency signals which are transmitted to the relay switchingcontact by means of the impedance circuit and/or an electrical loadand/or voltage source coupled to the relay switching contact.

This achieves the advantage that the properties of the switchingmonitoring device can be improved with regard to electromagneticcompatibility. The damping elements can in particular be adapted todampen a signal amplitude of the switching monitoring signal in order toreduce electromagnetic radiation of the switching monitoring signal inthe vicinity of the switching monitoring device and/or the relay.

In one example, the switching monitoring device comprises a seconddamping element and the signal output has a second output connection,which is followed by the second damping element, in order to dampenhigh-frequency signals which are transmitted by means of the impedancecircuit to the relay switching contact and/or an electrical load and/orvoltage source coupled to the relay switching contact.

In one example, the first damping element and/or the second dampingelement each have an inductance, and the respective inductance forms aminimum impedance for the switching monitoring signal in order toprevent a bypass of the switching monitoring signal via the electricalload and/or the voltage source.

This has the advantage that a switching of the relay switching contactbetween the first switching state and the second switching state can bereliably detected even with a low-impedance current source and/or alow-impedance electrical load. If a current path through the currentsource and the electrical load has a lower impedance than, for example,the capacitor connected in parallel to the relay switching contact, theswitching monitoring signal can flow via the current source and/or theelectrical load, so that switching the relay switching contact does nothave an impedance registered at the signal output or only influence suchimpedance to a lesser extent.

The inductances are advantageously adapted to have a low resistance inorder to minimize power losses when a current flows through theinductance occurs. In one example, the inductances are adapted to have atotal load current, which flows through the relay switching contact andis determined by the power of a voltage source and an impedance of aload applied to the relay switching contact. The inductances can bearranged together on a coil core, in particular a magnetic core, and inparticular form a current-compensated choke. The inductances canfurthermore be nested in one another with winding directions directedopposite one another in order to form the highest possible push-pullimpedance for the switching monitoring signal.

BRIEF DESCRIPTION OF THE DRAWINGS

Further exemplary implementations of the principles described herein areexplained with reference to the accompanying figures. They show:

FIG. 1 shows a switching monitoring device in an example;

FIG. 2 shows a switching monitoring device in an example;

FIG. 3 shows a switching monitoring device in an example;

FIG. 4 shows signal forms when a relay is activated by means of theswitching monitoring device in an example;

FIG. 5 shows an event sequence when a relay is switched on by means ofthe switching monitoring device in an example;

FIG. 6 shows an event sequence when a relay is switched off by means ofthe switching monitoring device in an example; and

FIG. 7 shows a schematic representation of a switching monitoring devicefor monitoring a switching operation of a relay switching contact of arelay.

DETAILED DESCRIPTION

FIG. 1 shows a schematic representation of a switching monitoring device100 for monitoring a switching operation of a relay switching contact101 of a relay 103. The switching monitoring device 100 has a controller105 which is adapted to produce a control signal for switching the relayswitching contact 101 and an excitation signal.

The switching monitoring device 100 further comprises an impedancecircuit 107 having a signal input 109 and a signal output 111. Thecontroller 105 is adapted to apply the excitation signal to the signalinput 109. The impedance circuit 107 is adapted to convert theexcitation signal into a switching monitoring signal and to output theswitching monitoring signal at the signal output 111 for applying on therelay switching contact 101.

In addition, the controller 105 is adapted to detect a change in asignal present at the impedance circuit 107, in particular theexcitation signal and/or the switching monitoring signal, and todetermine a switching operation of the relay switching contact 101 whenthe signal change is present.

The relay 103 is provided to transmit signals in a first frequency rangeand the switching monitoring signal is in a second frequency range,wherein the second frequency range has higher frequencies than the firstfrequency range. Furthermore, the impedance circuit 107 has a higherimpedance in the first frequency range than in the second frequencyrange.

The controller 105 further comprises a signal generator 113, which isadapted to produce the excitation signal in the second frequency range.The impedance circuit 107 is adapted to galvanically separate the relayswitching contact 101 from the signal generator 113 and/or thecontroller 105.

The controller 105 also comprises a measuring circuit 115 for monitoringthe change in the excitation signal. The measuring circuit 115 has acurrent sensor 121 which is connected between the signal generator 113and the impedance circuit 107. The current sensor 121 is adapted todetect a current flow between the signal generator 113 and the impedancecircuit 107 and to provide it to the controller 105 as a measuredcurrent value. Furthermore, the controller 105 is adapted to detect achange in the current flow between the signal generator 113 and theimpedance circuit 107 on the basis of the measured current value.

The impedance circuit 107 comprises a transformer 117 with aprimary-side coil 119-1 and a secondary-side coil 119-2, wherein thesecondary-side coil 119-2 is connected in parallel to the relayswitching contact 101, and the primary-side coil 119-1 is connected tothe signal generator 113. Furthermore, the impedance circuit 107comprises a capacitor 123 which is arranged in series with thesecondary-side coil 119-2. The capacitor 123 is adapted to form areactance for alternating current voltage signals which are applied tothe relay switching contact 101.

Furthermore, the impedance circuit 107 is adapted to apply the switchingmonitoring signal in the form of high-frequency auxiliary energy, whichin particular has a frequency in the range from 10 kHz to 1 MHz to therelay switching contact 101.

Furthermore, the controller 105 comprises a switching controller whichis adapted to produce the control signal for switching the relayswitching contact 101 and to apply the control signal to a magnet system125 of the relay 103 in order to switch the relay switching contact 101.

In one example, the controller 105 is adapted to apply the controlsignal to the signal generator 113, and the signal generator 113 isadapted to produce the excitation signal with the switching signal.

Furthermore, the signal generator 113 is adapted to produce theexcitation signal in the form of a periodic clock signal, and thecontroller 105 is adapted, based on the constant period of theexcitation signal, to detect a time interval between the generation ofthe excitation signal and a change in the excitation signal when theimpedance at the signal output 111 changes, in order to detect aswitching time delay of the relay switching contact 101.

The controller 105 also includes a control output 127 and the controller105 is adapted to provide a status signal at the control output 127,which is active after the relay switching contact 101 is switched on andis inactive after the relay switching contact 101 is switched off.

The controller 105 further comprises a control input 133, via which thecontroller 105 can be supplied with electrical energy. In particular,the controller 105 can be adapted to receive electrical energy in theform of a direct voltage in the range from 3 V to 24 V.

FIG. 2 shows a schematic illustration of a switching monitoring device100 for monitoring a switching operation of a relay switching contact101 of a relay 103 in an example. The signal input 109 is bipolar with afirst input connection 201-1 and a second input connection 201-2 and thesignal output 111 is bipolar with a first output connection 203-1 and asecond output connection 203-2. Furthermore, a first capacitor 205-1 isarranged between the first output connection 203-1 and the first inputconnection 201-1 and a second capacitor 205-2 is arranged between thesecond output connection 203-2 and the second input connection 201-2 inorder to capacitively couple the switching monitoring signal the relayswitching contact 101.

Furthermore, the impedance circuit 107 comprises an inductance 207,which is connected downstream of the first capacitor 205-1, wherein theinductance 207 forms an oscillatable system with the first capacitor205-1 between the first output connection 203-1 and the first inputconnection 201-1.

FIG. 3 shows a schematic representation of a switching monitoring device100 for monitoring a switching operation of a relay switching contact101 of a relay 103 according to the example shown in FIG. 1 .

In addition, the switching monitoring device 100 comprises a firstdamping element 301-1 and a second damping element 301-2. The signaloutput 111 has a first output connection 203-1 and a second outputconnection 203-2, wherein the first damping element 301-1 is connecteddownstream of the first output connection 203-1 and the second dampingelement 301-2 is connected downstream of the second output connection203-2, in order to absorb high-frequency signals, which are applied tothe relay switching contact 101 by means of the impedance circuit 107and/or an electrical load 129 and/or voltage source 131 coupled to therelay switching contact 101.

The first damping element 301-1 and the second damping element 301-2each have an inductance 303-1, 303-2, which forms a minimum impedancefor the switching monitoring signal in order to prevent a bypass of theswitching monitoring signal via the electrical load 129 and/or thevoltage source 131.

FIG. 4 shows a schematic illustration of signal forms 400 when a relayis activated by means of the Switching monitoring device. At a firstpoint in time t1, a relay control signal is applied to anelectromagnetic relay coil of the magnet system of the relay. A coilvoltage 401 is correspondingly applied to the electromagnetic relaycoil. When the coil voltage 401 is applied to the electromagnetic relaycoil, a coil current 403 in the electromagnetic relay coil increases.

Furthermore, from the point in time t1, the signal generator of theswitching monitoring device produces the excitation signal 405 in theform of a square-wave signal, which in particular has an exclusivelypositive signal amplitude. By means of the impedance circuit, theexcitation signal 405 is converted into the switching monitoring signal407, which is applied to the relay switching contact. From the point intime t2, the switching monitoring signal 407 has the signal form of theexcitation signal 405.

Up to the point in time t2, the relay switching contact is in the firstswitching state and is accordingly electrically non-conductive orhigh-resistance. The total resistance that can be detected at thetwo-pole signal output of the impedance circuit can be determined by theexternal wiring consisting of an electrical load and/or a voltagesource. Furthermore, in one example, the damping elements, in particularin the form of inductances, can contribute to the total resistance.According to the total resistance, a current flow can be detectedbetween the signal generator and the impedance circuit by means of thecurrent sensor.

From time t2, the relay switching contact switches from the firstswitching state to the second switching state, wherein the time intervalbetween t2 and t3 determining a bounce duration of the relay switchingcontact. When the relay switching contact is switched, the switchingmonitoring signal 407 breaks in in the form of a voltage at the relayswitching contact. The total resistance at the signal output of theimpedance circuit changes accordingly, since the electrically conductiverelay switching contact with the capacitor arranged parallel to therelay switching contact has a lower impedance compared to theelectrically non-conductive relay switching contact. The change in thetotal resistance can produce a change in a primary-side signal at thesignal input or the signal generator, which can be, for example, achanged current amplitude that can be detected by means of the currentsensor.

The controller is adapted to detect the change in current at time t2and, accordingly, to detect a switching of the relay switching contactat time t2. The controller can also be adapted to switch off the signalgenerator and, accordingly, the excitation signal 405 at time t5.Alternatively, the controller can be adapted to continuously produce theexcitation signal 405 in order to continuously apply the switchingmonitoring signal 407 to the relay switching contact. In particular, theexcitation signal 405 can be produced in the time interval 42 betweenthe time t5 and the time t7.

In one example, the controller is adapted to control the signalgenerator cyclically in order to produce the excitation signal 405 atrecurring intervals and to detect the switching state of the relayswitching contact. The controller can be adapted accordingly

-   -   using an absolute amplitude value and/or effective amplitude        value of an amplitude of the excitation signal 405 to detect        whether the relay switching contact is in the first switching        state or in the second switching state. Accordingly, with a        periodic check of the relay switching contact by means of the        Switching monitoring device, it can be ensured, for example,        that the relay switching contact is electrically conductive.

When the relay switching contact is switched to the second switchingstate, the controller produces a status signal 409 at the control outputin order to produce feedback on the switching of the relay switchingcontact.

Switching off the relay by changing the relay switching contact from thesecond switching state to the first switching state can be implementedby switching off the relay control signal at time t7. From time t7, thesignal generator can be switched on in order to produce the excitationsignal 405 and accordingly to apply the switching monitoring signal 407to the relay switching contact. The signal generator can be switched offat time t10.

The relay switching contact begins to open from time t8 and accordinglydisconnect the electrical connection via the relay switching contact.From time t9, the switching contact is completely open and no longerelectrically conductive. An arc between the opening contact points ofthe relay switching contact can be extinguished from time t9.

A time interval between times t2 and t3, in which the relay switchingcontact bounces, and a further time interval between times t8 and t9, inwhich an arc is formed at the relay switch contact, can vary for eachswitching operation. The signal generator remains switched on beyond therespective time interval in order to be able to detect the timedeviation of the respective time interval and/or the complete activationor deactivation process of the relay switching contact.

The controller can also be adapted to determine a number of bouncesand/or a bounce duration on the basis of the signal curve of theexcitation signal 405 and the signal curve of the switching monitoringsignal 407. Furthermore, the control can be adapted to compare thedetermined bounce duration and/or the determined number of bounces witha respective limit value.

The controller can also be adapted to detect the coil current 403 and todetermine an armature impact time t6 on the basis of the temporalamplitude profile of the coil current 403 when the switching signal isapplied to the electromagnetic relay coil. The armature impact time t6can be defined in that the magnet system has deflected an armature ofthe relay to the maximum and, accordingly, a working air gap between ayoke of the relay and the armature has been completely overcome.Furthermore, at the armature impact time t6, a mechanical contactbetween buttons of the relay switching contact can be subjected to amaximum possible compressive force. The controller can be adapted todetermine the point in time t2, from which the relay switching contactis electrically conductive, and the point in time of armature impact t6.

Furthermore, the controller can be adapted to determine a time intervalΔ1 between time t2 and time t6. With the signal curves of the excitationsignal 405, the switching monitoring signal 407 and/or the coil current403 in the time interval Δ1, the controller can be adapted to determinetypical relay parameters. Furthermore, the control can be adapted todetermine the typical relay parameters continuously or at periodicintervals in order to determine wear, a failure probability and/or amaintenance or replacement time of the relay from a time profile of therelay parameters. The controller can also be adapted to detect aswitching cycle of the relay.

Furthermore, the controller can be adapted to switch the status signal409 active from the time t4 and to increase a signal amplitude of thestatus signal 409 accordingly. Furthermore, the controller can beadapted to switch the status signal 409 inactive from time t8 and toreduce a signal amplitude of the status signal 409 accordingly.

FIG. 5 shows an event sequence 500 of switching on a relay by means ofthe switching monitoring device in one example. The event sequence 500begins with the start of switching on 501, which is characterized inthat a relay control signal is present at the control input of thecontroller. The control then acts on the magnet system of the relay withthe activation signal, so that the relay 503 is activated. The signalgenerator is then switched on in order to produce the clock signal,identified by Clock On 505. After the switch-on delay of the relay, therelay switching contact closes and the relay has switched on 507.

When the relay switching contact is closed, the current flow through therelay switching contact changes and accordingly through the signaloutput of the impedance circuit, so that a current change 509 occurs onthe input side. By switching on the transit time determination 511, aswitch-on time of the relay switching contact can be determined andrecorded by the control.

The control then switches the feedback to active 513 by switching thestatus signal 409 active at the control output. This completes theswitching on of the relay and the event sequence 500 ends 515.

FIG. 6 shows an event sequence 600 of switching off a relay by means ofthe switching monitoring device in one example. The event sequence 500begins with the start of switching off 601, which is characterized inthat a relay control signal is no longer present at the control input ofthe controller. Correspondingly, the control signal is not applied tothe magnet system of the relay. The signal generator is then switched onin order to produce the clock signal, identified by clock on 605. Afterthe switch-off delay of the relay has elapsed, the relay switchingcontact opens and the relay has switched off 507.

When the relay switching contact is opened, the current flow through therelay switching contact and accordingly through the signal output of theimpedance circuit changes, so that a current change 609 occurs on theinput side. By switching off the running time determination 611, aswitch-off time can be detected by the control in order to determine arunning time of the relay based on the difference between the switch-ontime and the switch-off time.

The control then switches the feedback to inactive 613 by switching thestatus signal 409 to inactive at the control output. The switching offof the relay is thus complete and the event sequence 600 ends 615.

FIG. 7 shows a schematic representation of a switching monitoring device100 for monitoring a switching operation of a relay switching contact101 of a relay 103. The switching monitoring device 100 furthercomprises two coupling capacitors 701, 703 and a signal monitoringcircuit 705. The capacitors 701, 703 are connected on the input side tothe signal output 111 and connected on the output side to the signalmonitoring circuit 705. Furthermore, the coupling capacitors 701, 703are adapted to capacitively couple a signal applied to the relayswitching contact, in particular the switching monitoring signal, to thesignal monitoring circuit 705.

This achieves the advantage that the impedance circuit 107 caninductively couple the switching monitoring signal to the relayswitching contact 101 and a change in the switching monitoring signalcan be capacitively detected by means of the coupling capacitors 701,703 and provided to the signal monitoring circuit 705. The signalmonitoring circuit 705 can be adapted to detect a change in theswitching monitoring signal and to provide the status signal.Furthermore, the coupling capacitors 701, 703 and/or the signalmonitoring circuit 705 can be part of the controller 105 and/or beintegrated into it.

LIST OF REFERENCE NUMBERS

-   -   100 Switching monitoring device    -   101 relay switching contact    -   103 relay    -   105 control    -   107 impedance circuit    -   109 signal input    -   111 signal output    -   113 signal generator    -   115 measurement circuit    -   117 transformer    -   119-1 primary side coil    -   119-2 secondary side coil    -   121 current sensor    -   123 capacitor    -   125 magnet system    -   127 control output    -   129 electrical load    -   131 power source    -   133 control input    -   201-1 first input port    -   201-2 second input port    -   203-1 first output port    -   203-2 second output port    -   205-1 first capacitor    -   205-2 second capacitor    -   207 inductance    -   301-1 first damping element    -   301-2 second damping element    -   303-1 inductance    -   303-2 inductance    -   400 waveforms    -   401 coil voltage    -   403 coil current    -   405 excitation signal    -   407 switching monitoring signal    -   409 status signal    -   t1 point in time    -   t2 point in time    -   t3 point in time    -   t4 point in time    -   t5 point in time    -   t6 point in time    -   t7 point in time    -   t8 point in time    -   t9 point in time    -   t10 point in time    -   41 time interval    -   42 time interval    -   500 event sequence    -   501 start Power on    -   503 control relay    -   505 cycle on    -   507 relay switched on    -   509 change in current    -   511 switch on runtime determination    -   513 feedback active    -   515 end of power-up    -   600 event sequence    -   601 start switch off    -   603 switch off relay    -   605 cycle on    -   607 relay has switched off    -   609 change in current    -   611 switch off runtime determination    -   613 Feedback inactive    -   615 End of switch-off    -   701 coupling capacitor    -   703 coupling capacitor    -   705 signal monitoring circuit

What is claimed is:
 1. A switching monitoring device for monitoring aswitching operation of a relay switching contact of a relay, theswitching monitoring device comprising: a control terminal configured toapply a control signal for switching the relay switching contact to therelay switching contact; a controller configured to produce anexcitation signal; and an impedance circuit having a signal input and asignal output, wherein the controller is configured to apply theexcitation signal to the signal input, wherein the impedance circuit isconfigured to convert the excitation signal into a switching monitoringsignal and to output the switching monitoring signal at the signaloutput for application to the relay switching contact, wherein thecontroller is further configured to detect a change in a signal presentat the impedance circuit and, if the change in the signal is present, todetect the switching operation of the relay switching contact, andwherein the signal input is bipolar with a first input connection and asecond input connection, and wherein the signal output is bipolar with afirst output connection and a second output connection, and wherein afirst capacitor is arranged between the first output connection and thefirst input connection, and wherein a second capacitor is arrangedbetween the second output connection and the second input connectionsuch that the second capacitor capacitively couples the switchingmonitoring signal to the relay switching contact.
 2. The switchingmonitoring device according to claim 1, wherein the signal present atthe impedance circuit comprises one or more of the excitation signal orthe switching monitoring signal.
 3. The switching monitoring deviceaccording to claim 1, wherein the relay is configured to transmitsignals in a first frequency range and the switching monitoring signalis in a second frequency range, and wherein the second frequency rangehas higher frequencies than the first frequency range, and wherein theimpedance circuit has a higher impedance in the first frequency rangethan in the second frequency range.
 4. The switching monitoring deviceaccording to claim 3, wherein the controller is configured to producethe excitation signal in the second frequency range.
 5. The switchingmonitoring device according to claim 1, wherein the controller comprisesa measuring circuit configured to monitor a change in the excitationsignal.
 6. The switching monitoring device according to claim 5, whereinthe controller comprises a signal generator configured to generate theexcitation signal.
 7. The switching monitoring device according to claim6, wherein the measuring circuit has a current sensor connected betweenthe signal generator and the impedance circuit, wherein the currentsensor is configured to detect a current flow between the signalgenerator and the impedance circuit and to provide a measured currentvalue of the current flow to the controller, and wherein the controlleris configured to detect a change in the current flow between the signalgenerator and the impedance circuit based at least in part on themeasured current value.
 8. The switching monitoring device according toclaim 6, wherein the impedance circuit is configured to galvanicallyseparate the relay switching contact from one or more of the signalgenerator or the controller.
 9. The switching monitoring deviceaccording to claim 1, wherein the impedance circuit has an inductanceconnected downstream of the first capacitor, and wherein the inductanceforms an oscillating system with the first capacitor between the firstoutput connection and the first input connection.
 10. The switchingmonitoring device according to claim 1, wherein the impedance circuithas an inductance connected downstream of the second output connection,wherein the inductance forms an oscillating system with the secondcapacitor between the second output connection and the second inputconnection.
 11. The switching monitoring device according to claim 1,further comprising: a first coupling capacitor, a second couplingcapacitor, and a signal monitoring circuit, wherein the first couplingcapacitor is configured to connect to the first output connection andthe second coupling capacitor is configured to connect to the secondoutput connection, wherein the first coupling capacitor and the secondcoupling capacitor are connected to the signal monitoring circuit andare further configured to convert the switching monitoring signal into atest signal and to provide the test signal to the signal monitoringcircuit, and wherein the signal monitoring circuit is adapted to detecta change in the test signal and to detect the switching operation of therelay switching contact when the change in the test signal is present.12. The switching monitoring device according to claim 1, wherein thecontroller is configured to connect to the control terminal and applythe control signal to the control terminal.
 13. The switching monitoringdevice according to claim 12, wherein the controller comprises aswitching controller configured to produce the control signal forswitching the relay switching contact and to apply the control signal toa magnet system of the relay to switch the relay switching contact. 14.The switching monitoring device according to claim 12, wherein thecontroller is configured to apply the control signal to a signalgenerator that is configured to produce the excitation signal with thecontrol signal.
 15. The switching monitoring device according to claim14, wherein the signal generator is adapted to generate the excitationsignal as a periodic clock signal, and wherein the controller is adaptedto detect a switching time delay of the relay switching contact,including detecting a time interval between the generation of theexcitation signal and a change in the excitation signal when animpedance at the signal output changes, based on a constant period ofthe excitation signal.
 16. The switching monitoring device according toclaim 1, wherein the controller has a control output, wherein thecontroller is configured to provide a status signal at the controloutput, and wherein the status signal is active after the relayswitching contact is switched on and is inactive after the relayswitching contact is switched off.
 17. The switching monitoring deviceaccording to claim 1, further comprising: a first damping element thatfollows the first output connection of the signal output, wherein thefirst damping element is configured to dampen high-frequency signalsapplied to the relay switching contact via one or more of the impedancecircuit, an electrical load, or a voltage source coupled to the relayswitching contact.
 18. The switching monitoring device according toclaim 17, further comprising: a second damping element that follows thesecond output connection of the signal output, wherein the seconddamping element is configured to dampen high-frequency signals appliedvia the impedance circuit to one or more of the relay switching contact,the electrical load, or the voltage source coupled to the relayswitching contact.